Method of forming electrodes for electrolytic condensers



Patented Sept. 1, 1936 I METHOD OF FORMING ELECTRODES FOR ELECTROLYTIC CONDENSERS Julius Edgar Lilienfeld, Winchester, Mass., assignor, by mesne assignments, to The Magnavox Company, Fort Wayne, Ind., a. corporation of Arizona No Drawing. Application February 14, 1934, Serial No. 711,287

20 Claims. (01. 175-315) My nv ion rel tes t a m th f forming tion of the film. Hence the high degree or resistfilmed metal electrodes specially adapted for use ance to hydration (conversion to hydroxide form) in electrolytic condensers. is advantageous as it follows that this type of This pp t i in p t a ntinuat 0n 0 film possesses a high degree of resistance to my copending application Ser. No. 670,084, filed det rior ti May 9, 1933, now Patent No. 2,021,455. In the case of a filmed anode employed in an My invention has for its principal object the electrolyte, the extent of hydration will depend provision Of an improved hod Of f n upon the resistance of the film to hydration and electric films on filming metals, such as alum nu upon -the tendency of the electrolyte to produce or tantalum, to secure films having an exceedhydration. 1o ingly high resistance and stability even at voltages In my o di application Sen N 711,2 6 of 0- d higher. Whether alernating' filed of even date herewith and since issued as di c u for indefinitely long p s of Patent No. 1,986,779,1have described an improved time whether employed in operation continuously type of film-forming electrolyte having a very 13 or intermittently, and which will have a fast minimum tendency to produce hydration of di-'15 comeback after idling. electric films employed therewith.

Specific objects and features will be made ev1- 1 My present invention l t primarily t an dent as the description progresses. improved method of forming the active type of Before proceeding to describe my improlfed film, to produce a dielectric film which initially method, I Will first point out the distinction WhlCh has an extremely low leak and low power 1055 and 20 exists betw e o yp of films layers which which will also be exceptionally resistant to hy-.

can be produced. dration and hence to deterioration. In the de- Ohe yp Which I refer to as being an scription and claims I will, for purposes of confilm, is characterized by the fact that it is subvenience, employ the term film-forming" stantially 'a dielectric and remains a dielectric exclusively in the restricted sense of referring a Whether Operated in y moist in an to capability of forming the active type of film electrolyte. Such films can be obtained, for exdescribed b pl by l t yz n anode f a fi m The second type, which I refer to as an inmetal, such as aluminum, in a solution of boric, active film or layer, is characterized by being citric, tartaric, or succinic acid, with or without hydratable and is highly insulating only when 39 the addition of a small amount of a salt of such dry and exposed t a dry medium s a film an acid 01 8. base. This treatment, in the 09.58 Of or layer can be formed by electrglyzing an anode an aluminum electrode, fo a p produces of a filming-metal in a solution of sulfuric acid, what I believe to be an aluminum oxide film conphosphgrjc acid, a carbonate, etc" and in other s t of highly Organized and associated alumi' ways. A characteristic of this type of layer is 35 num Oxide mo e produced from initially that it can be formed to any thickness without formed aluminum hydroxide molecules by the acsparking. The thickness is t limited by the tion of the high intensity electrostatic field existformin voltage t can b regulated and is s all the Surface of the anode during the formpendent upon the concentration and temperature 40 c Operation. w i links together aluminum of the forming electrolyte, the current density, to

oxide molecules so as to resist subsequent converand the duration of treatment sion into the hydroxide form. Films of this type A d ub1e ]ayer type of electrode having very have 2. thickness Of the order of magnitude Of useful properties can be made as follows: A film- 10- to 10 mm., and their thickness is detering-metal electrode is first coated with an "inac- 4.5 mined by t e ma Voltage applied in formtive, or highly hydratable, layer, preferably to a i t limit imposed by the Vo age not being thickness of about 1/1000 mm.; thoroughly exceeded even thou h e VOitage is applied for washed; and then subjected to a forming treatan unlimited period of timemerit to produce an active film. The active film A p p formation will result in an anode will be found to be underimposed beneath the in- Coated W 8 him so highly resistant to v active layer. The order of steps is irreversible, 5o. sion to the hydroxide form that i Will ve th that is, the active film cannot be formed first and same capacity whether exposed to dry air or to then be coated with the inactive layer,since formair saturated with moisture. Hydration of the ing progresses inwardly, and such an attempted film causes an increase of capacity, power loss, procedure will only result in destroying the active and leakage current, and thus causes deteriorafilm. 55

When in the hydrated state, the thin outer layer of such a double-layer electrode is', even at low voltages, quite conductive and will not act as a dielectric, and the capacity will be controlled by the underimposed active film. A transition layer appears to exist between the inactive layer and the active film, so that capacity measurements show a somewhat smaller capacity than on corresponding active non-underimposed films, but the inactive layer proper does not act as a seriescapacity.

The outer layer behaves as a porous coating, which is permeable to fluid or plastic electrolytes utilized for forming or healing the active film. I do not mean that the outer layer is necessarily permeable to the electrolyte as a whole, since there will be sufficient permeability if the layer is rendered conductive and if healing of the underlying active film is permitted. The outer layer thus serves as a coating to mechanically protect the active film, without interfering with the forming or healing thereof, and will also prevent solid particles which may be present in an electrolyte in which the electrode is employed from coming in contact with the surface of the active film and thus reducing the sparking voltage.

One method of forming an inactive layer, given by way of example, is as follows: The electrode body, such as an aluminum sheet, is first thoroughly cleansed. Cold distilled water may be utilized for cleaning. Hot distilled water or any medium having an alkali characteristic should be avoided, as this will produce a thin film on the surface of the aluminum which will prevent proper success of the forming step. Hot distilled water which has been acidulated with a small amount of an acid, such as phosphoric acid or boric acid, is preferred.

The electrode is then operated as an anode in the electrolyte of 1/10 normal phosphoric acid at a temperature of 30-35 C., with the voltage regulated to produce a current density of about 5 ma. per square cm., for 30-45 minutes. If a higher current density is applied then the time may be shortened in proportion, or even more than in proportion, inasmuch as the thickness of the layer increases somewhat faster at higher ".current densities than at lower ones.

The electrode is now thoroughly washed to remove all traces of the electrolyte from the formed layer, as the presence of phosphoric acid will interfere with the subsequent formation of an active film. The formed surface may be sprayed with hot or boiling distilled water for 10-20 seconds, or immersed successively in two containers of boiling distilled water for ten minutes each. Washing can be accomplished withcold distilled water, but will take much longer...

The formed surface of the electrode will, as the; result of this treatment, have the appearance of being coated with a tough skin.

Proceeding now with a description of my .present invention, which is concerned primarily with the formation of an active film having improved characteristics, the following method is employed by me:

The electrode body, whether or not ithas previously been coated with an inactive layer, is electrolyzed in a hot viscous semi-dry film-forming electrolyte. The electrode may previously be subjected to a preliminary forming operation in a nonviscous electrolyte capable of producing an active film,but such a step is purely optional and is unnecessary.

Before proceeding to describe the actual treatment steps which I have found it advantageous to employ, I will describe what is meant by the semi-dry viscous type of electrolyte to which I refer.

The dryness and viscosity of this electrolyte are such that the number and mobility of the hydroxyl ions present in the electrolyte will be as low as possible without preventing film formation and so will favor the building up of a very highly organized non-hydratable film.

It is my view that the attempt to obtain optimal condenser performance of a layer may be represented as an attempt to form tightly bound aluminum oxide chains from initially formed aluminum hydroxide molecules. This result I1 believe to be due to the high intensity electrostatic field existing at the surface of an electrode during the formation of a film. The greater the number and mobility of hydroxyl ions present in the electrolyte adjacent the surface of the film, the greater the hindrance to the formation of stable aluminum oxide molecule chains from which the OH radical is excluded. On the other hand, a certain hydroxyl ion concentration adjacent the electrode surface being formed is desirable in order to secure proper formation, and this I believe is due to the fact that aluminum hydroxide is formed as an intermediate in the formation of the aforesaid aluminum oxide chains.

Irrespective of theory, I have found that best results are obtained by employing a semi-dry viscous film-forming electrolyte.

Use is made by me of homogeneous highly polymerized plastic reaction products of water soluble polyhydric alkyl compounds and water 3 soluble polybasic film-forming acids. The products are esters which are polymerized by the interlinking of the molecules into complex forms made possible by the presence of a plurality of replaceable radicals in both the polyhydric and polybasic materials utilized. The preferred compositions are uniform and have no suspended phase of solid particles, such as crystals; and are plastic in the sense of being coherent, amorphous and semisolid, in contradistinction to viscous liquids which do not retain their shape to any practical extent. The physical characteristics noted refer to the properties at room temperature.

The greater the number of hydroxyl and hydrogen radicals taking part in the esterification and polymerization, the greater the viscosity of the product as compared with that of the polyhydric alkyl compound employed; and this applies to hydroxyl radicals in the acid when a hydroxyacid is used, since esterification can occur between such acid molecules.

At elevated temperatures, such as 85-95 C., these compositions have a syrupy consistency, which I denote by the. term viscous, and may be-readiiy utilized in the formation of electrodesto be dipped therein.

I'prefer to use the lower and less complex polyhydric alcohols, including both straight alcohols and alcohol ethers; such as the simple 65 glycols, for example diethyiene glycol; and glycerol; but higher polyalkyl and polyhydric water soluble alcohols may also be used, such as pentaerythrol, sorbitol, mannitol and dulcitol.

As examples of polybasic film-forming acids ohms/ch1 and preferably below aosasro Succinic acid is an example oi dibasic acid containing no hydroxyi t will form ,a plastic product with hydric), but with diethylene glycol it it will form a viscous product which is In the latter case a plastic product obtained by employing a more complex s. junction with the succinic acid,

It will be evident that by employ ng of acids it is possible to obtain products ous degrees of plasticity from any given hydric compound.

I prepare the polymerized, plastic, product by mixing the selected "n pound and polybasic acid in approsire cular proportions such that there droxyl (OH) radical to each ac (3". 2 This proportionality may be varied w h' ly wide limits. By employing a polyhydroxy compound above the a strictly molecular proportional product can be made less vmcous, desirable in the case of product wise might be harder to handle ti The mixture is heated and d1 --eat ing the boiling point rises. The temperature is maintained at the boiling point a boiling point is reached at which suiilcier tion has occurred so that the product ing to room temperature will be a position, preferably homogeneous s acid crystals. Heating will, g quired for a period of one to four w ing upon the rate at which heat is the mixture.

By employing a suitable catalyst the ne ization can be facilitated.

Water will be produced as one be largely driven out by the prolonged 1 e and hence the product may be termed 2 Products produced with an acid lower hydroxyl ion concentration than and in order to obtain a suitable electrolyte I accordingly increase ion concentration by adding a em. water soluble alkali salt of a fihr. such as borax, sodium citrate, sodi etc.; or a water soluble base, our hydroxide or potassium hydroxide kali hydroxide, with or without of a small amount of water. necessary to employ a small all-10L due to the high degree of dryness of composition resulting from the prolor ing, the amount depending upon :3 tea which the composition has been use of a salt, rather than a base,

poly

of saponification. A salt which w with the formation of an active fir avoided, such as chlorides, sulfate i phates, and hence I specify a ing acid.

The salt or base may be introdu polymerized product has been cbta elevated temperature at which or may be introduced into the prior to reaction and polymerizati-r The specific resistance of electrolyte so produced may be Y dication oi the desired hydroxyl so tion, and I ordinarily adjust the a specific resistance in excess oi ohms/cook is obtained at 90 0., which temperatru e is'within the range ordinarily employed in iorming the active film as previously described. at room temperature such electrolytes will have specific resistance within the approximate rangeof 100,000-500,000 ohms/ch1 due to possessing an extremely high temperature coeillclent resistance.

A. suitable electrolyte can be prepared as follows, given by way of example: Heat together 62%, by weight of glycerol and 38% oi boric Several hours heating will be required to reach a composition boiling between 17 3-17? 0., at temperature polymerization will read- The temperature is then lowered to ut 100 C. and a solution of equal parts by e ght of water and borax, 5% of each relato the weight of glycerol, is added. The resultant product will be viscous and possesses :peciilc resistance or about 6400 ohms/ch1 at its a second example, an electrolyte can be p ared by heating together 50%, by weight, o. diethylene glycol, 23% of boric acid, and 27% ct tetraborate, to produce a reaction and polymerization product which will be plastic at rcerzi temperature. At 90 C. the product will be a syrupy liquid and the specific resistance will about 2,006 ohms/ch1 Poiyznerized products obtained by use 01' citric or tartaric acid have a higher viscosity and sistance than those obtained by use of -d, but may be reduced in specific re- "e the same manner, and also may be a by adding them to boric acid type ucts have been made up and whose tance it is desired to raise. A higher spereslstance than that oi. the products dein the two above examples is desirable l a peak formation voltage or higher than cnd since issued as Patent No. 1,986,779. .e foregoing description of specific electrolv as given by way of illustration and I do not cl be limited thereby, since in accordance 1y invention I may utilize, generally, filmg electrolytes which are viscous and semiat the elevated temperatures employed. I

p; r, generally, to employ electrolytes having a resistance above 1500 ohms/cm and p below iilfififlohmslcm at the hot forming temperature, since the specific resistance itself. a factor of importance in permitting ltation to secure advantages, to a degree, with my invention. Electrolytes having specific resistances substantially in excess of 10,000 ohms/c211 may be employed, although with an attendant increase in the amount or power required for forming a film.

an active him may first be substantially i the aforesaid hot viscous electrolyte by ting the electrode as an anode on direct t at a voltage which is gradually raised to where it is somewhat in excess of the service voltage at which the electrode designed to operate when embodied in a com r. when designed to operate on altercurrent; it should be borne in, mind that the :tMi-t voltage rating (as shown bye. volt meter) be specified so that the peak of the A. C.

service voltage will he somewhat lower than the peak of the formation voltage, and hence that a margin above the peak service voltage should he provided. dine margin to he provided, to take care of fluctuations and surges, should not he unnecessarily great, as the thickness of the dim depends upon the forming voltage and the thicker the film the less its capacity. When forming an electrode to have a service rating of ill) volts A. C. for use on commercial lines, the D. C. forming voltage should preferably not be higher than 175-200 volts, the excess voltage above the 155 peak voltage of the scrvicerating being the margin provided. Similarly, an electrode designed for a service rating of 220 volts A. C. is preferably formed at about 380 volts D. C.

By a hot electrolyte I mean one which is at a temperature substantially in excess of room temperature. I normally employ a temperature of about 85-95 C., but even higher temperatures may be used.

The D. C. formation period depends upon the formation current, and may be completed in about five minutes with a current density of 6-8 ma. per square cm. for condensers that are to be operated at 110 volts A. C. For higher voltage condensers a longer period will be required due to the higher peak forming voltage needed. After the desired peak forming voltage has been reached, the voltage is held constant and theleak current will then drop as the formation continues. Formation is continued until the desired low leak is obtained. A leak of less than 6.3 ma. per square cm. in the hot electrolyte can be obtained, but it is of course not necessary that a leak as low as this be secured.

The electrode is neat subjected to A. C. treatment in the same or similar hot viscous elec= trolyte. Where a number of electrodes are being simultaneously formed in the electrolyte tank, this may be conveniently done icy dividing the electrodes into two opposed groups, each group having the same area, connecting the two groups to the respective end terminals of a transformer coil that is insulated from ground, and energizing the coil to produce the A. C. voltage and current necessary for the treatment.

The peak A. C. voltage used in this step should preferably be very close to the peak D. C. voltage employed in the preceding step, in order to obtain a film having a minimum power loss, and ordinarily. I employ a peak voltage which is 'just slightly less. The A. C. treatment is continued for about 1-5 minutes.

The D. 0. formation in the hot viscous electrolyte may be omitted, in whole or in part, ir= respective of whether or not there has been a prior formation step. That is, the active him may be formed partly or entirely by A. C. in the hot viscous electrolyte. However, this will necessitate a regulation of the A. C. voltage until the capacity current due to the initial high capacity has been reduced, in order to prevent an excessive and undesirable flow of current. I prefer to substantially form the film with D. C. and then to finish up with A. C. in the manner described.

The A. C. treatment may be omitted and the film formed as far as possible with D. C. in the hot viscous electrolyte. Such a procedure will result in a better film than if no formation occurred in the hot viscous electrolyte, the him not increasing its capacity in operation, but the film will have a higher power loss when accepts employed in a condenser and greater heating will occur.

It will thus be evident that formation in the hot viscous electrolyte, whether with D. C. or A. 0., gives an improved result as such; and an improved result is contributed by A. C. formation as such.

The forming operation described above will r suit in a low powerloss film suitable for idiate use, the characteristic depending upon the procedure fo1lowed, but in accordance with my invention I employ in addition the following subsequent treatment.

I have found that it is advantageous to coat the formed active film with a viscous hydrolyzahle film-forming electrolyte which, will be retained to a certain extent by the film, and then to hydrolyze this viscous electrolyte by washing in water. The washing will remove surplus electrolyte and leave a hydrolyzed portion absorbed or adsorbed in the film, which improves the film, apparently by repairing imperfections .or by facilitating repair during a subsequent forming step or when the electrode is operated in a condenser.

In order that this step may be performed with a minimum of extra labor, it is advantageous to employ a viscous hydrolyzable electrolyte in the preceding forming or treating. step, so that the electrode may immediately thereafter be washed to secure the hydrolyzed product attached to the film. From the production standpoint it is advantageous, as a matter of economy, to heat the electrodes after removal from the forming tank, but before washing, for a few minutes in a tunnel kept at a temperature of nearly 100 0., collecting the viscous electrolyte which drips on for reuse in the forming tank.

lire reaction and polymerization products of polyhydric alcohols, and the like, and film-forming acids, which I have described as suitable electrolytes for the hot treatment of an electrode,

are characterized by being hydrolyzabie and in addition are adhesive so that they. will readily cling to the active layer. The products obtained by reaction and polymerization of diethylene glycol or glycerol and boric acid, with or without the addition of similar products, will be found especially suitable, since they readily hydrolyze and are quite adhesive.

Hence the step of hydrolyzing may be readily performed by conducting the preceding hot treatment in the aforesaid type of electrolyte and thereafter washing the electrode, preferably in hot distilled water to save time, although cold water may be employed.

This step may be employed to advantage whether or not the particular preceding forming steps described herein are utilized and may be omitted with an attendant loss of the improvement efiected.

The next step which I prefer to employ is to treat the filmed electrode, operated as an anode, with. D. C. for a short interval of time in-a cold film-forming electrolyte. This step may be termed a finishing D. C. surge treatment, and ordinarily will last from 2 to 5 minutes at a voltage substantially equal to the preceding peak forming voltage.

I prefer to employ a saturated aqueous solution of a film-forming acid, such as bone acid, citric acid, tartaric acid, or succinic'acid, etc. A sate urai/ed aqueous solution of boric acid, which I ordinarily prefer to employ, will have a specific resistance of about 2i,0oil-ohms/cm at 25 C.

indicating a low hydroxyl avoidance of sparking of high voltage.

Omission of this D. C. surge treatment in a cold electrolyte will result in a film having a higher power loss than when the treatment is given, and this is particularly true with respect to films designed to operate at 220 volts or higher. Hence the finishing step is important in securing a film of high emciency, although not essential in securing a film of good stability.

After washing and drying oi the electrode it is in condition for assembly in a condenser in the usual manner.

The various steps which I have set forth, while separately valuable, are not merely cumulative when employed in the combination of steps deion concentration and exposed films at quite scribed, but mutually contribute in an associative manner to enable a dielectric film of unusual properties to be obtained.

when double-layer type electrodes are formed utilizing in full sequence of "steps which I have described, and assembled in condensers by employing the improved type of electrolyte described in my copending application Ser. No. 711,286, filed oi even date herewith, and since issued as Patent No. 1,986,779, condensers are obtained which can be operated indefinitely at high voltages without heating, without change oi capacity, and with an extremely low power loss.

A particularly advantageous feature is that condensers tor. alternating current use may be made up in'this manner which can be successrully utilized for power factor correction of electrical equipment operated at commercial voltages, an objective which has long been sought. Such condensers require no negative bias superposed upon the electrolyte to prevent deterioration of the dielectric film, and may be operated indefinitely, either continuously or with idling periods, without heating-and without change of capacity or other sign trio. These condensers can be operated at voltages 0! 100-440 trodes and hence do not need to be connected in a series hook-up ior ordinary commercial line voltages.

whatI claim is as iollowsz 1. In a method 0! forming a filming-metal electrode, the steps comprising subjecting the electrode body to DC. treatment in a hot viscous semi-dry hydrolyzable film-iorming'electrolyte, subjecting the electrode to A. C. treatment in the same type of hot electroi'ytethereby obtaining a low power loss tained by the film, and subjecting the electrode to a D. C. surge treatment in a cold film-forming be employed. subjecting the electrode to A. C.

treatment in the same type oi hot electrolyte at a peak voltage about equal to said D. C. peak voltage, thereby obtaining a low power loss film, washing the electrode to hydrolyze portions of the electrolyte retained by the film, and subjecting the electrode to a D. C. surge treatment at a voltage about equal to said D. C. peak voltage in a cold film-forming electrolyte oi sufilciently high of a deteriorating dielecand higher across opposing elecfilm, washing the elec trode to hydrolyze portions 0! the electrolyte re- 3. In a method of forming a filming-metal electrode, the steps comprising subjecting the electrode body to D. C. treatment in a hot viscous semi-dry hydrolyzable film-forming electrolyte at a peak voltage substantially greater than the peak service voltage at .which the electrode is to be employed, subjecting the electrode to A. C. treatment in the same type of hot electrolyte at a peak voltage about equal to said D. C. peak voltage, thereby obtaining a low power loss film, washing the electrode to hydrolyze portions of the electrolyte retained by the film, and subjecting the electrode to a D. C. surge treatment in a cold aqueous solution of a substantially pure film-forming acid.

4. In a method oi forming a filming-metal elecelectrolyte retained by the film, and subjecting the electrode to a D. C. surge treatment in a cold aqueous solution of a substantially pure filmiorming acid.

5. In a. method of forming a filming-metal electrode, the steps comprising electrolyzing the electrode body ina hot viscous semi-dry hydrolyzable film-forming electrolyte at a peak voltage substantially in excess oi the peak service voltage at which the electrode is to be employed, and washing the electrode to hydrolyze portions 01 the electrolyte retained by it. 6. In a method 01 forming a filming-metal electrode, the steps of iorming a substantially nonhydrstable dielectric film on the electrode, coating the film with a viscous semi-dry hydrolyzeble film -iorming electrolyte, and washing the electrode to hydrolyze portions or the electrolyte retained by the film.

"7. In a method of forming a filming-metal electrode, the steps of forming a substantially nonhydratable dielectric film on the electrode, coating the filmwith a viscous semi-dry hydrolyzable' iilm-dorming electrolyte, washing the electrode to hydrolyze portions or the electrolyte retained by the film, and subjecting the electrode to a D..'C. surge treatment in a cold film-forming electrolyte.

8. In a method of forming a filming-metal electrode, the step oi electrolyzing the electrode in a hot viscous semi-dry film-forming electrolyte bath maintained at a temperature at least equal to about 85 C., at an A. C. peak voltage substantially in excess of the peak service voltage at which the electrode is to be employed. 9. In a method of forming a filming-metal electrode,the steps 0! electrolyzing the electrode body in a hot viscous semi dry film-forming electrolyte bath maintained at a temperature at least equal to about 85 0., first with D. C. and then with A. C. at peak voltages about equal to each other and substantially in excess of the peak service voltage at which the electrode is to be employed.

10. In 'a method of forming a filming-metal electrode, the step of electrolyzing the electrode in a hot viscous semi-dry film-forming electrolyte having a specific resistance of at least about 1,500 ohms/cm. at the temperature employed.

11. In a method of :iorming a filming-metal l 76 specific resista ce to prevent sparking. electrode. the step or electrolyzing the electrode 1 in a hot viscous semi=dry illm=torming electrolyte having a specific resistance of about 1,500-10,000 ohms/cm at the temperature employed.

12. In a. method of forming a filming-metal electrode. the step of subjecting the electrode to A. C. treatment in a hot viscoussemi-dry filmtorming electrolyte having a specific resistance of at least about 1,500 ohms/cm at the temperature employed.

13. In e. method 01' forming a filming-metal electrode. the step of subjecting the electrode to A. C. treatment in a hot viscous semi-dry filmiorming electrolyte having a specific resistance of about l,500-=l0,000 chins/cm at the temperature employed, at a peak voltage substantially in excess of the peak service voltage at which the electrode is to be employed.

14. In a method of forming a filming-metal electrode. the step of electrolyzing the electrode in a hot viscous semi-dry film-forming electrolyte consisting essentially of a reaction and polymerization product of a'w'ater soluble polyhydric allryl compound and a, water soluble polybasic filmforming acid, said electrolyte having a hydroxyl ion concentration adjusted to impart a substantially reduced specific resistance not less than about 1,500 ohms/cm at the temperature em- Pieced.

15. In a method of forming a filming-metal electrode, the step of electrolyzing the electrode .in a hot viscous semi-dry film-forming electrolyte consisting essentially of a homogeneous plastic reaction and polymerization product of a lower polyhydric alcohol and an acid of the class conshting of boric cold, citric acid, and tartaric acid, with suihcient cdmed material of the class concisting of water soluble bases and alkali salts of film-forming acids to import to the electrolyte a reduced specific resistance insumciently low to cause sparking oi the electrode.

16. In a method of forming a filming-metal electrode, the step of subjecting the electrode to A. C. treatment at a temperature of about 85-95 C. in a viscous semi-dry film-forming electrolyte having a specific resistance of about 1500-1011011 chins/cm? at 90 0.; said electrolyte consisting essentially of s motion and polymerization prodnot of boric acid and n 'polyhydric alcohol oi the class consisting of diethylene glycol and glycerol, with admixed sodium tetraborate.

17. In a method of forming a filming-metal electrode, the steps comprising electrolyzing the electrode in a hot viscous semi-dry film-forming electrolyte at a peak voltage substantially in excess of the peak service voltage at which the electrode is to be employed, thereby obtaining a low power loss film, and subjecting the electrode to a D. C. surge treatment in scold film-forming electrolyte at a peak voltage about equal to the peak voltage utilized in the aforesaid step.

18. In a method of forming a filming-metal electrode, the steps comprising subjecting the electrode to A. C. treatment in a hot viscous semidry film-forming electrolyte at a peakvoltage substantially in excess of the peak service voltage at which the electrode is to be operated, thereby obtaining a low power loss film, and subjecting the electrode to a D. C. surge treatment in a cold. aqueous film-forming electrolyte having a high specific resistance, at a peak voltage about equal to the peak voltage utilized in the aforesaid step.

'19. In a method of forming a filming-metal electrode, the steps comprising subjecting the electrode to D. C. treatment in a hot viscous semidry illm-Iorming electrolyte, subjecting the electrode to A. C. treatment in a hot electrolyte of the same type, thereby obtaining a low power loss film, and subjecting the electrode ton D. C. surge treatment in a cold film-forming electrolyte consisting of a substantially pure saturated aqueous solution of a water soluble film-forming acid.

20. The method of forming a double-layer type of electrode especially adapted for use in electrolytic condensers for continuous operation on alternating current at high voltages, comprising the steps of electrolyzing an aluminum electrode in about 1/10 normal phosphoric acid to produce a protective layer thereomwashing the electrode to remove traces of the acid, subjecting the electrode to A. C. treatment in a hot viscous semidry film-forming electrolyte, and subjecting the electrode to a D. C. surge treatment in a. cold film-forming electrolyte of sufllcient specific resistance to prevent sparking. 1

JULIUS EDGAR LILIENFELD. 

